Modern Machine Shop

SEP 2018

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Page 44 of 220

ADDITIVE INSIG MMS SEPTEMBER 2018 42 Understanding Industrial 3D Pr AUTHO | Timothy Simps Professor of Engineering Design & Manufac Pennsylvania State Univer wear study, a TiAlN-coated carbide end mill run- ning in a thin-walled, Inconel 718 support struc- ture experienced chipped edges after the first run. The flutes' corner radii cracked within 1 minute. In fully dense material, flaking took 3 minutes. Other tools performed similarly. In one case, corner radii fractured in 0.33 minute in the thin- walled support structures. So while the forces are less, constant back-and-forth between the thin walls and hollow sections has significant and detri- mental effects on tool life. The data call into question the use of standard feeds and speeds for removing thin-walled support structures. So, proceed cautiously when machining thin-walled support structures from metallic parts made via additive manufacturing. Alternatively, insist on fully dense support structures before machining. Even then, tool life may be short. In closing, I want to thank Prof. Ed De Meter and Dr. Guha Manogharan, as well as the graduate students who assisted us. Our paper is available in the Journal of Manufacturing Processes Figure 2: Moving averages for milling forces Realize your vision From quick prototypes to serial production, we got you covered . ExOne Binder Jetting ยจ Visit ExOne at IMTS in Chicago, IL from September 10 - 15, 2018 Booth 432308 (West Hall)

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